waiko group company profile issue 16-1 150309waikogroup.com/images/stories/waiko/waiko group company...

WAIKO GROUP

COMPANY HISTORY KEY MILESTONES YEAR

KEY MILESTONES

1982 Registration of partnership under the name of Waiko Engineering Works. The initial business activity of Waiko Engineering Works was in the provision of machining services primarily servicing the mining industry.

1989 Waiko Engineering Works was then converted into Waiko Engineering Works Sdn Bhd.

1989 Commenced manufacturing of Spun Pile End Plates by Waiko Engineering Works. 1992 Incorporation of Naga Elit Sdn Bhd. 1995 Incorporation of Projek Cekap (M) Sdn Bhd. 1996 First export sales of Spun Pile End Plates to Taiwan. 1997 Waiko Group moved to its present manufacturing facility in Pusing, Perak. 1998 Commenced the design and manufacturing of Formwork Systems. In the same year,

the Group also ventured unto fabrication of other products, including rolling stock under frames, steel structures and related steel products.

2000 Commenced the design and manufacture of Mechanized Formwork Systems. 2002 Secured the project together with CAD2000 to manufacture two Self-Reacting Tunnel

Formwork Systems for the Penchala Link tunnel construction project in Selangor. 2003 Secured the project to manufacture Slurry Pipe System for the SMART project in

Kuala Lumpur. 2003 Commenced the provision of Geotechnical Engineering Solutions by Projek Cekap

(M) Sdn Bhd. 2003 Provision of Geotechnical Engineering Solutions for the Ipoh-Rawang Electrified

Double Tracking project. 2003 Waiko Engineering Works Sdn Bhd obtained ISO 9001:2000 accredited by SIRIM and

UKAS. 2004 CAD 2000 Asia Sdn Bhd formed as a joint venture with CAD2000 Europe, with

Waiko Group holding a 50.0% equity stake for Design and Technical Assistance on Formwork Equipment.

2004 Won the project to design and manufacture together with CAD2000 for Tunnel Lower Road Deck Formwork System for the SMART project in Kuala Lumpur.

2004 Waiko Group exports Self-Reacting Tunnel Formwork System to Milan, Italy. 2005 Waiko Group together with CAD2000 exports its Self-Reacting Tunnel Formwork

System for Lane Cove Tunnel in Sydney, Australia. 2005 Secure the project to manufacture Form Traveller Formwork System for Bridge No. 2

over Jalan Kuching, Kuala Lumpur, Malaysia. 2005 Secured the project to design and manufacture Slurry Pipe Systems for MRT Circle

Line stages 4 and 5 in Singapore, and Koln Nord Sud Stadtbahn Railway Tunnel in Germany.

2005 Won the project to manufacture Pre-cast Segmental Form Traveller for the Incheon Second Bridge construction project in Korea.

2005 Received Letter of Recommendation from Wayss & Freytag (Malaysia) Sdn Bhd for Formwork System and Slurry Pipe System designed and manufactured for use in the SMART project, Kuala Lumpur.

2006 Secured the project to manufacture Pre-Cast Free Cantilever Method (FCM) Formwork and Trolley Manipulator System for Incheon Second Bridge construction project in Korea.

2006 CAD2000 Asia & WAIKO undertook and completed the design and manufacture of Self-Reacting Tunnel Formwork Systems for Johnstone’s Hill Tunnel in New Zealand.

2006 WAIKO and CAD2000 have successfully design and manufacture of Pylon Self-Climbing Jump Formwork System and Incremental-Launching Formwork System for the construction of the Sungai Johor Cable-Stayed Bridge.

2006 Secure the project to design and manufacture of Slurry Pipe System for the Vancouver Seymour-Capilano Twin Tunnel water transfer project in Canada.

2006 Modification and upgrade of existing Full Span Segmental Launcher System for use in bridge construction works for the Dubai Light Rail Transit (LRT) project in Dubai.

2006 Provision of Geotechnical Engineering Solutions for the Ipoh-Rawang Electrified Double Tracking project.

2007 Secure the project to manufacture Form Traveller Formwork System for Jambatan Pasir Pulau, Kuala Terengganu, Terengganu.

2007 Supply, Fabricate and Deliver Structural Steel Roof For AGL Sub-Station for New Doha International Airport, Qatar.

2007 Secure the project to manufacture, test and install 8 sets of Segment Mould Formwork System for Palm Jebel Ali Main Bridge and Crescent Bridge in Dubai, UAE.

2007 Secure the project to manufacture 2 sets of Full Span Launcher for Palm Jebel Ali Main Bridge and Crescent Bridge in Dubai, UAE.

2008 Secure the project to design, manufacture and supply 2 sets of Smoke Duct Formwork c/w Carrier and Scissor Lift for North South Bypass Tunnel, Brisbane for “Leighton Contractor and Baulderstone Hornibrook – Bilfinger Berger Joint Venture” (LBB Joint Venture).

2008 Secure the project to design, manufacture, test and install 6 sets of Segment Mould Formwork System for “Project R881/2C – Comprehensive Improvement of Parallel Roads” in Dubai, UAE.

2008 CAD2000 Asia & WAIKO undertook and completed the design and manufacture of Self-Reacting Tunnel Formwork Systems for Boggo Road Busway Alliance Tunnel in Brisbane, Australia.

2008/09 Secure the project to design, manufacture and commission 3 sets of Self-Reacting Tunnel Formwork Systems for Berapit Tunnel, part of the Electrified Double Track Project – Ipoh to Padang Besar, Malaysia.

BUSINESS ACTIVITIES

• The business activities of Waiko Group are depicted in the figure below:

MARKET ACCESS

As at 30 September 2008, Waiko Group has a cumulative customer base of

approximately 153 customers across a total of 9 countries (including Malaysia) since the commencement of business operations in 1982.

The overseas customers spread across 8 countries - Korea - Qatar - Canada - UAE, Dubai - Germany - Australia - Singapore - New Zealand

Waiko Group currently services the following types of customers:

- Operators of Tunneling Works - Operators of Segmental Bridge Construction - Property Developers - Manufacturers - Intermediaries such as agents and distributors.

Business Activities of Waiko Group

Projek Cekap Sdn Bhd

Cad2000 Asia Sdn Bhd

Design of Mechanized Formwork Systems

Geotechnical Engineering

Solutions

Trading

Tunnel Formwork Systems

Bridge Formwork Systems

Stone Column Systems

Steel Products

Waiko Engineering

Works Sdn Bhd

Manufacture of Mechanized Formwork

Systems and Related Products

Tooling and Fabrication

Manufacture of Steel Products

Tunnel Formwork Systems

Slurry Pipe Systems

Bridge Formwork Systems

Spun Pile End Plates

Pipe Flanges

FACTORY LAYOUT

Land Area : 19 acres/ 76,890m2 Factory Built Up Area : 5.3 acres/ 21,180m2

o 33m x 200m – 2 buildings o 24m x 120m – 3 buildings o 33m x 60m – 3 buildings o Future extension 33m x 200m – 2 buildings

MACHINERY AND EQUIPMENTS Machinery and Equipments No. of Units

- Autocad 2007/2008 - Solidworks 3D Modelling - Hydraulic Press Machine 500Ton - Hydraulic Press Machine 300Ton - Hydraulic Press Machine 200Ton - Shearing Machine - Rolling Machine - Drilling Machine - Tapping Machine - Lathe Machine - Welding Machine – Semi Automatic MIG/MAG - Welding Machine – Submerged Arc Welding 1000A - CNC Machining centres - Semi automatic multi-cut lathe machine - Numeric control flame cutting machine - 50Ton Crawler Crane - 35Ton Crawler Crane - 25Ton Crawler Crane - 20Ton Tough Terrain Mobile Crane - 20Ton Mobile Crane - 1x5Ton ABUS double girder overhead crane - 2x7.5Ton ABUS double girder overhead crane - 2x6.3Ton DEMAG double girder Gantry crane - 1x5Ton Single girder overhead crane - 2x5Ton double girder overhead crane - 1x8Ton double girder overhead crane

3 seats 1 seat

3 1 3 5 6 8 2

10 40 5

6 sets 3 sets 2 sets

5 1 1 1 1 2 4 1 4 1 1

Business Activities, Products and Services (A) Tunnel formwork system

Self reacting tunnel formwork system Full round tunnel formwork system Smoke Duct table formwork system

(B) Bridge Formwork System

Self climbing jump formwork Incremental launcher method Full Span Segmental Launcher (Span-By-Span) Derrick Crane FCM Segment Mould Launching Gantry Form Traveller formwork Self Climbing Movable Safety Screen System Rebar Cage Automatic Machine Concrete Distribution Arm

(C) Slurry Pipes and Tunnel Rolling Stock

Slurry Pipes OD200mm to 500mm Service Pipes OD50mm to OD200mm Grouting Car

(D) Manufacturing – Spun Pile End Plates & Flanges (E) Soil Improvement – Stone Column (F) Tooling and General Structural Fabrication (G) Rolling Stocks and Hydraulic Rail-Gears

(A) TUNNEL FORMWORK SYSTEM

The self reacting tunnel formwork system provides a light weight, flexible and efficient formwork system for Tunnels that are excavated by “Drill and Blast Method” or “Roadheader Excavation Method”. The system can be customized for circular or non-circular geometrical tunnel cross section. The major advantage of is that the self-reacting tunnel formwork equipment is installed with Eletro-Hydraulics components, Pneumatic or electric Vibrators and Concrete Distribution system(CLD). All of the components are robust and designed to withstand the harsh conditions in the tunnel. In addition, the complete equipment can be controlled and managed with a crew of 4 to 5 persons with a press of a button for advancing, setting-up and stripping. The concrete distributor is able to distribute the concrete at a rate ranging from 20m3/hour to 40m3/hour, and the typical working cycle during the concrete lining is 24 hours for a typical 10m to 15m concrete lining. The typical working cycle is as follows:

• Place concrete 5 hours • Cure concrete 10 hours • Strip, clean, move & re-set 6 hours • Float time 3 hours

Project Experience

Penchala Tunnel, Kuala Lumpur (Year 2003) Metroline Tunnel, Milan, Italy (Year 2003) Lane Cove Tunnel, Sydney (Year 2005) Johnstone Hill Tunnel, Auckland (Year 2006) Boggo Road Busway Alliance Tunnel, Brisbane, Australia (Year 2008) Berapit Tunnel, part of the Electrified Double Track Project – Ipoh to Padang Besar,

Malaysia. (Year 2009)

CUSTOMIZED TUNNEL FORMWORK SYSTEM

The tunnel formwork system can also be customized for special cross section and design requirement. A typical example is the customized tunnel formwork for the Lower Roaddeck for the first in the world “Storm Water Management and Road Tunnel, SMART” in Kuala Lumpur. The formwork is designed to 120meter and it has to take into account the limited space in the lowerdeck, obstructions from the diameter 500mm slurry pipes, deviation in the tunnel drive, tight 250m radius alignment curve and road camber of the lowerdeck. With this formwork, the cycle time and manpower requirement has been reduced significantly compared with the conventional formwork. Project Experience

SMART Tunnel, Kuala Lumpur (Year 2006)

TUNNEL FORMWORK SYSTEM – SMOKE DUCT FORMWORK TABLE

Another interesting customized tunnel formwork system was secured in year 2008 for the design, manufacture and supply of 2 sets Smoke Duct Formwork c/w Carrier and Scissor Lift for North South Bypass Tunnel, Brisbane. The formwork was customized to special cross section and design requirement. The total length of the formwork is 240m. With this formwork system, the cycle time and manpower requirement has been reduced significantly compared with the conventional formwork. Project Experience

North South Bypass Tunnel, Brisbane (Year 2008)

(B) BRIDGE FORMWORK SYSTEM

1. SELF CLIMBING JUMP FORMWORK

The self climbing jump formwork system is specifically designed for construction of Concrete Pylon for cable-stayed bridge and concrete shaft typically for buildings and silos. The design are based on concrete pressure as per DIN 18218. Since most Pylons are at least 100 meter high, this system is specifically designed with extra safety features and installed with Electro-hydraulics components, pneumatic vibrators and concrete distribution unit to enhance automation, reduce manual labour and increase productivity.

Project Experience

Design and operate 4 sets of self-climbing 6m Jump formwork system for Sg. Johor Cable Stayed Bridge, Johor, Malaysia in 2007.

2. INCREMENTAL LAUNCHING METHOD(ILM) Incremental launching systems are designed to sequentially launch the precast concrete bridge segments across a span, utilizing lifting and sliding mechanism during bridge construction.

In the incremental launching method, bridge segments are cast as a box girder at the work site and subsequently launched by sliding them into the final position with the aid of hydraulic cylinders and sliding bearings. Project Experience

Manufacture 2 sets of Incremental Launcher 48m Span for Sg. Johor Cable Stayed Bridge, Johor, Malaysia in 2007.

3. FULL SPAN SEGMENTAL LAUNCHER (SPAN BY SPAN)

The full span segmental launcher formwork system is a highly effective system to launch concrete segment. In this method, the entire span of the concrete segments which consist of several pieces of segments is temporary supported by the segmental launcher. After all the precast segments are in the correct position, the span will be post-tensioned. Project Experience

1800MT capacity Full Span Launcher for Palm Jebel Ali, UAE Main and Crescent Bridge.

The span erection sequence is shown below

Launching Girder Palm Jebel Ali, Dubai Main & Crescent Bridges Project

1'st Span Erection Date : 13. Sep. 2008.

Page : 1 of 5

Launching Girder Palm Jebel Ali, Dubai Main & Crescent Bridges Project

1'st Span Erection Date : 13. Sep. 2008.

Page : 2 of 5

Waiko Company Profile

4. PRECAST FCM FORMWORK & TROLLEY MANIPULATOR SYSTEM


The precast FCM formwork and trolley manipulator system is a unique system specifically designed for precasting of concrete segment. Traditionally, the precast FCM formwork is only able to cater for constant concrete segment depth and width. In contrast, this system is able to efficiently and successfully to cater for variable segment depth and width. The formwork is also equipped with hydraulic cylinders and trolley manipulator for set-up, stripping and transporting the precast segment. Project Experience

Incheon Grand Bridge, Korea (Year 2006) Main Bridge and Crescent Bridge, Palm Jebel Ali, Dubai (Year 2008) Project R881/2C – Comprehensive Improvement of Parallel Roads in Dubai, UAE.

(Year 2008)


5. DERRICK CRANE


The Derrick Crane which is also known as the Precast Segmental Form Traveller is designed for a maximum precast segment length of 5 m and load capacities between 100 and 300 metric tonne. The DC equipment is installed with Electro-Hydraulics, PLC control, Electric Hoists for lifting of the precast segments, and specially designed hydraulic system for adjusting the alignment and positioning of the precast segment. The advancing of the formwork equipment is controlled by electro-hydraulics system. The Derrick Crane can be adapted to almost any new cross section for future projects. Project Experience

Incheon Grand Bridge, Korea (Year 2006)

6. LAUNCHING GANTRY – SEGMENTAL

The erection of the span starts from the other end, starting with the first segment as a guideline for the remaining segments. Each new segment is temporary stressed to the previous erected segment by means of temporary tension bars. This is mainly to obtain a minimum contact pressure between the segments. The whole span is finally adjusted to the correct level (vertically) and alignment (transversally) by the Gantry, and the permanent stressing operation can take place.


7. FORM TRAVELLER SYSTEM(FT)

The form traveller system is acclaimed for enhancing the cost-effectiveness of bridge projects worldwide. The system is lightweight, versatile, easy to assemble and operate, rolling forward on rails, the system can be reset quickly and easily. The form traveller is used for free cantilever construction of post-tensioned box girder - and cable-stayed concrete bridges. Engineering to international standards, the system provides an exceptionally rigid formwork, with a maximum deflection of less than 25mm at full loading. The Standard formtraveller is designed for a maximum segment length of 5 m and load capacities (concrete and formwork) varying from 250t to 400t. The steel weight depends on the cross-section of the bridge in question, but will normally vary from about 25t to 65t correspondingly. The Standard formtraveller may be adapted to suite almost any cross-section, and is easily adjustable during operation to variations in segment length (up to 5 m), section height, web thickness, and deck width. Project Experience

Bridge No. 2 over Jalan Kuching, Kuala Lumpur, Malaysia in Year 2005. Jambatan Pasir Pulau, Kuala Terengganu, Terengganu in Year 2006


8. SELF CLIMBING MOVABLE SAFETY SCREEN SYSTEM

The self climbing safety screen offer added safety and protection in the construction of high rise building. The safety screen is constructed by steel and it is manufacture to meet safety standard in Europe and Australia.


9. REBAR CAGE AUTOMATIC MACHINE

The automatic rebar cage fabrication machine will enhance productivity and reliability, and proven to enhance profitability for construction project in the long run. Project Experience

Incheon Grand Bridge, Korea (Year 2006)


10. CONCRETE DISTRIBUTION ARM

Project Experience

Project R881/2C – Comprehensive Improvement of Parallel Roads in Dubai, UAE. (Year 2008)


(C) SLURRY PIPE SYSTEM & TUNNEL ROLLING STOCK


Project Experience

SMART Tunnel, Kuala Lumpur in 2004/2006 MRT Tunnel Circle Line stage 4 and 5, Singapore in 2005/2006 Koln Nord Sud Stadtbahn Railway Tunnel, Germany in 2006 Vancouver Seymour Capilano Water Transfer Tunnel, Canada in 2006


(D) MANUFACTURING – SPUN PILE END PLATES & FLANGES

Spun Pile End Plates

Industrial Flanges and Adaptors


(E) GEOTECHNICAL ENGINEERING SOLUTION

PROJEK CEKAP (M) SDN. BHD. Is a leading specialist Contractor carrying out innovative ground improvement works and piling works. Types of Ground Improvement Works and Piling Works undertaken includes:-

Vibro Replacement / Stone Columns (Design and Installation / Installation) Prestressed Spun Pile (Supply / Supply and Install)


Advantages of Stone Columns 1. More economical than piling, percentage of saving per meter square can range

from 20% to 70%, depending on the pile spacing, pile length and pile capacity.

2. Significantly simplifies substructure design and construction as compared to piling. Eliminate the needs of providing continuos pilecap / individual pilecap, cutting / lengthening of pile, reinforcement for pilecap etc. A layer of capping sand is already adequate for load transfer and achieve arching effect in the stone column.

3. Significantly reduces consolidation settlement of subsoil to 2 to 5 times lesser

than without any treatment, or by prefabricated vertical drains.

4. Accelerate rate of consolidation. The rate of consolidation is very much shorter than prefabricated vertical drains. (In the range of about 6 months for PVD, can be reduced to about 2 months with stone columns)

5. Immediate Increase of shear strength and friction angle of treated soil, increase

both short term and long term stability and thus eliminate the need of counter weight berm.

6. No waiting period after installation as compared to PVD. Embankment

construction can commence immediately after installation of stone column to full height of embankment.

Installation Stone Column


(F) TOOLING AND GENERAL STRUCTURAL FABRICATION

General Fabrication Rolling Stocks

Fabrication and Installation for Steel Roof Structure in New Doha International Airport in

2007. Fabrication and Installation for Factory Building in Klang, Malaysia. Fabrication and Installation of ERL station at Salak Tinggi and Bandar Tasek Selatan,

Malaysia.


(G) ROLLING STOCKS & HYDRAULIC RAIL-GEARS

Manufacture 50 numbers BCF (Bogie Container Flat) Wagon for KTMB. (Year 2002) Manufacture 4 numbers of BCF Wagon for Balfour Beatty Rail for Rawang-Ipoh

electrification project. (Year 2004)


HYDRAULIC RAIL- GEAR AND EQUIPMENT

Manufacture 4 numbers of Rail-Gear for Balfour Beatty Rail for Rawang-Ipoh electrification project. (Year 2004-2005)

MALAYSIA TAIWAN ITALY KOREA CHINA

3

FACTORY INTRODUCTION

Height resolution laser plotter


4


5

Segment Turning device


6

Vacuum lifting device

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